Warn 71983, Installation Instructions Manual

Page 1: ...ng plow Alw Alw Alw Alw Alwa a a a ays ys ys ys ys perform regular inspections and maintenance on the plow mechanism fasteners cable and related hardware Alw Alw Alw Alw Alwa a a a ays ys ys ys ys replace all worn or damaged parts before operating Ne Ne Ne Ne Nev v v v ver er er er er operate this WARN product with damaged or missing parts Alw Alw Alw Alw Alwa a a a ays ys ys ys ys drive slowly ov...

Page 2: ...rior to installing the plow mount Right hand and left hand nomenclature throughout this document is with reference to side viewed from the operators position Table of Contents I Tools Required 3 II Torque Specifications 3 III Parts List 3 IV Installation 4 A Plow mount installation 4 B Plow support installation 11 NOTE Plow system is not intended for commercial use or applications Plow system may ...

Page 3: ...olt 1824 2 7 16 dia x 1 long bolt 7676 4 7 16 flat washer 710123 2 7 16 dia nylon lock nut 70566 6 1 2 dia x 3 long bolt 29060 6 1 2 dia nylon lock nut 69376 1 5 8 dia x 4 1 2 long bolt 69515 1 5 8 dia nylon lock nut 3693 2 Spacer 67622 4 5 8 outer dia x 3 4 long bronze spacer 68716 6 1 outer dia x 1 5 8 long spacer 72685 4 1 4 inner dia x 1 4 long spacer 69373 1 Plow roller fairlead 69375 1 3 1 4...

Page 4: ...ne so install a WARN winch kit Roller fairlead that comes with the winch kit does not need to be installed This kit comes with a special fairlead to be used with plow 2 Begin by locating and removing the two rear bumper mounting bolts See Figure 1 and 2 Figure 1 Location of bumper bolts to remove Figure 2 Remove bumper bolts both sides Location of bolt to remove ...

Page 5: ... Locate the left and right mounting brackets in the kit Insert the four 5 8 dia x 3 4 long bronze spacers between the flanges of the mounting brackets with the 3 8 dia x 2 long carriage bolts See Figure 3 Figure 3 Install carriage bolt and bronze spacer to bracket Figure 4 Install brackets to vehicle lower frame Figure 5 Install bracket hardware washer both sides Install mounting bracket tab on in...

Page 6: ...orward toward bumper Trimmed opening should be approximately 3 8 1 2 wide by 3 long Related figures show the right hand side of vehicle viewed from the top through the hood opening Cut can be made most easily from the front of the vehicle through the front wheel fender opening See Figure 6 7 and 8 Figure 6 Location of material to be trimmed RHS shown Figure 7 Trimmed material Figure 8 Material rem...

Page 7: ...ure 9 Locate the top of the brace along the outer side of the frame member See Figure 10 and 11 Figure 9 Installation of brace LHS shown Figure 10 Locate top of brace to outside of upper frame tube Figure 11 Lower holes of brace fasten to mounting bracket Brace Vehicle Storage Tray Frame Member ...

Page 8: ...the top of the brace to the frame member using 1 4 x 1 wide x 1 3 4 long U bolt 1 4 flat washer and 1 4 nylon nut Do not tighten any hardware See Figure 13 9 Repeat the steps for mounting the brace for the other side See Figure 14 Figure 12 Brace fastened to mounting bracket Figure 13 Upper holes of brace fastened to vehicle frame tube Figure 14 Repeat brace mounting for other side Vehicle Storage...

Page 9: ...unting brackets centered on the plow support flanges See Figure 17 With the brackets centered to the support and square to the vehicle and screw drivers in place tighten down all mounting hardware in the following order 7 16 hardware mounting bracket to frame 5 16 dia x 1 1 2 wide x 2 1 4 long U bolt mounting bracket to bumper tube 3 8 dia x 2 long carriage bolts mounting bracket to brace 1 4 x 1 ...

Page 10: ...n routing the cable in or out of the rollerfairlead Operating the winch without the hook and hook strap can cause extreme bodily injury to the extremities such as the hands and fingers The winch needs to be off and switched to freespool when handling the winch cable without the hook WARNING Figure 20 Install grip clip onto winch hook Grip clip Winch hook Winch cable Clevis pin WARNING Do NOT opera...

Page 11: ... is no position 3 for the arm stop An arm stop is not needed if this position is selected There is no way to predetermine which setting the arms should be set in as each vehicle will react differently with a plow installed thus the user must use trial and error It is recommended to start in position 1 as this will fit the majority of vehicles For vehicles with greater than normal ground clearance ...

Page 12: ... out the other flange See Figure 23 Terminate with a 1 2 dia nylon lock nut Tighten the nut until the nut and head of the bolt are resting against the surface of each outer flange The arm should rotate freely around the bolt 22 Place the end of each top arm between the outside flanges and align them to top arm position 1 See Figure 22 23 Slide a 1 2 dia x 3 long bolt through top arm position 1 in ...

Page 13: ... bolt head are firmly resting against either side of the flanges but loose enough that the roller rotates freely about the bolt See Figure 24 26 Install the assembled guide roller and brackets onto the plow support by inserting tangs through slots in the support See Figure 25 Then rotate guide roller assembly up to align tab holes to support top flange holes Fasten with 3 8 dia x 1 1 4 long bolt a...

Page 14: ...nut See Figure 27 28 Attach one of the latches to a latch bracket Use two 3 8 dia x 1 1 4 long bolt and 3 8 nylon nuts See Figure 27 and 28 for part orientation for right hand and left hand latch assemblies Figure 27 Latch assembly left hand side Figure 28 Latch assembly right hand side Latch Bracket Latch Latch Latch Bracket Detent pin Lanyard fastening location ...

Page 15: ...e 29 and 30 30 Install latch assembly to top edge of stand and up against the side of plow support See Figure 31 Figure 29 Install stand right hand side shown Figure 30 Install stand slot to plow support tab Figure 31 Install latch assembly to stand and plow support Stand Slot Plow Support Tab Assembled Latch ...

Page 16: ... inner dia x 1 4 long spacers on each of the 1 4 bolts making sure that the spacers are fully engaged in the slot of the latch assembly See Figure 33 33 Carefully push bolts back through until they are flush with the latch bracket See Figure 34 Figure 32 Install 1 4 bolts Figure 33 Install spacers on 1 4 bolts Figure 34 Push 1 4 bolts and spacer back flush 1 4 Bolts ...

Page 17: ... ends of the bolts with two 1 4 dia nylon lock nuts and 1 4 flat washers See Figure 37 Tighten just snug and then loosen 1 8 1 4 turn The stand should move freely up and down on the support If stand does not move freely then loosen additional incremental amounts Until latch and stand move freely Repeat from step 29 36 for other side Figure 35 Install retainer plate to plow support tab and engage F...

Page 18: ...h plow skids are in the blade Rock the support until both feet are flat on the ground At this point the feet skids and edge of the plow blade should all be resting flat on the ground If not adjust the plow skids or detent pins as needed CAUTION Use proper lifting techniques when lifting the plow support Bend at the knees not your waist and lift with your legs Lifting with poor technique can lead t...

Page 19: ...operly vertically If they are at various heights follow the steps below Bottom edge of support receiver is HIGHER than the bottom surface of the plow mount Check that the tires have proper air pressure If adjustable adjust the shock settings to raise the vehicle If the tire pressure is correct and the shocks are raised to there highest setting then lower the plow support by removing the detent pin...

Page 20: ...support fully engages into the plow mount 7 Turn off the vehicle set the parking brake and walk over to the plow support Check to make sure that the plow support receivers are fully engaged in the plow mount You may have to push on the plow support or pull on the plow to get the receiver to go in as far as possible 8 Pull the detent pin out in one of the legs firmly slide and lift the stand until ...

Page 21: ... in one of the stands lift the stand until it locks fully into the plow mount place the detent pin back into the bottom hole in the plow support See Figure 40 Repeat on the other side 5 Double check that the plow is fully engaged into the system Pull and push on the plow blade to ensure nothing on the plow mount or plow support moves The blade should be solidly attached to the vehicle 6 MANUALLY r...

Page 22: ...ing the plow from the vehicle 9 Drive to an area with level solid ground Turn off the vehicle set the parking brake and walk over to the plow support 10 Remove the winch hook from the quicklink on the plow base Route the cable over the roller on the plow support and drape hook and cable over bumper tube Do not hook to vehicle bumper See Figure 43 11 Remove the detent pin for one of the stands Drop...

Page 23: ...h the winch cable and drop the feet then manually pull the plow support out of the mounting receivers If you are having trouble getting a latch to engage the plow mount it may need some simple adjustment With the stands in the down position push the plow support receivers into the plow mount as far as it will go Loosen the two 3 8 dia bolts holding the latch to the latch bracket Raise the stand up...

Page 24: ...aler to order To find a dealer nearest you please call the WARN Dealer locator line at 1 800 910 1122 Lanyard Service Kit No 71685 ARM Service Kit No 71683 Latch Assembly Service Kit No 72846 Support Stand Service Kit No 72845 Latch Hardware Service Kit No 72847 Bronze Spacer Service Kit No 72866 ARM Spacer Service Kit No 71707 ...